2003-2008 Honda Pilot Tru-Cool LPD 4451 Power Steering & 4543 ATF Coolers Install

[blueintegraboy]

Please refer to this thread for Curt hitch install

My inspiration for this install came from a few threads found on this site. I wanted a clean, sturdy install without having to drill into the car. I ended up installing the brackets using the mounting points for the stock power steering cooler and optional ATF cooler.

I bought a Tru-Cool 4451 for my power steering cooler and Tru-Cool 4543 for my ATF cooler. The coolers come with enough hose and the only other thing I used were the hose clamps. You'll need to purchase 4 more hose clamps, at least for my install.

First you'll need to go to Lowes to buy 1" aluminum square tube (they come in 3ft lengths) and 3/4" aluminum channel x2 (they come in 40" lengths I believe). You'll need M6x1.00x65 bolts/washers x4, 0.257" ID nylon spacers 1" long x4, and bolts/washers/lock nuts x12 (to mount the coolers to the brackets and to mount the cross brackets to the main brackets). I chose to purchase stainless steel M6x1.00 bolts x12 instead of using the supplied bolts/nuts.

Making the brackets and mounting the coolers:

1. Cut the 1" square tube into 9" lengths x2.
2. Use the diagram below for the measurements I used. Remember measure twice, cut once.
3. Drills the holes in the main brackets, black dots mean you drill through both layers; red dots you drill though one layer.
4. Mount the main brackets with the 1" nylon spacers behind the "black" holes and against the mounting points using the M6x1.00x65 bolts
5. Measure the cross brackets against the main brackets, and cut to length, then drill the holes to line up with the "red" holes.
6. Tighten the bolts for the cross-main bracket mounting points. You'll need to remove the main bracket so this can happen. Make sure you get the correct angle for the cross-main bracket connections. (What I did was tighten the bottom cross bracket first while the main bracket was installed, then removed and tighten the top cross bracket)
7. Mark the cooler holes to the cross brackets, and drill. Finally mount the coolers to the cross brackets and install the whole assembly to the vehicle.

Making the connections:

1. I reused the top PS hose and placed a Magnefine inline filter to connect to top opening of PS cooler.
2. I also reused the bottom PS hose and place the 3/8" coupler (included in the kit) between the stock hose and connecting hose to bottom opening of PS cooler.
3. I installed a Magnefine inline filter to the top opening of the ATF cooler and cut to length a piece of hose that connects directly to the in-line fitting of the transmission (the stock hose clamp was a ***** to remove).
4. I cut to length the hose connecting the radiator out-line fitting to the bottom of the ATF cooler (again, the stock hose clamp was a ***** to remove).

[Armystrong]

It would be nice to see the connections and filters you used in your system. Nice write up.

[blueintegraboy]

Most of the connections can be seen in the 2nd pic. The only ones not seen are the tranny and radiator connections (when installing look for the tranny connection closest to the driver wheel, then trace back towards the radiator). It would have been tough to get a picture of those because of the limited space.

The filters used are mentioned in the first post. They are Magnefine 3/8" filters. They can be seen in the second and third pictures near the top of the coolers.


NB: DO NOT use the coupler included in the kit. Even with lots of teflon, it still leaked at the connection between the two pieces. Instead, purchase a 3/8" male-to-male barbed coupler/splicer (also can be purchased at Lowes).

[robs]

Great job and pics too!

I noticed you mounted the coolers very low in front of the condensor. I was always under the assumption you mount them high to avoid rocks and such flying up and hitting the coolers? How protected are the coolers by the bumper and grille in this arraignment?

Also, can you estimate how much fluid capacity the ATF cooler and hoses add to system? The 06-08 has a larger 4qt sump. The 03-05 is about a qt smaller. Any additional capacity is only a good thing.

Thanks!

[blueintegraboy]

Originally Posted by robs

Great job and pics too!

I noticed you mounted the coolers very low in front of the condensor. I was always under the assumption you mount them high to avoid rocks and such flying up and hitting the coolers? How protected are the coolers by the bumper and grille in this arraignment?

Also, can you estimate how much fluid capacity the ATF cooler and hoses add to system? The 06-08 has a larger 4qt sump. The 03-05 is about a qt smaller. Any additional capacity is only a good thing.

Thanks!

Thanks for the comments.

I mounted the coolers that low to have access of fresh air through the bumper. I was examining the AC condenser, I didn't find anything but bugs so I am not worried about rocks.

I estimate less than a quart of ATF was needed to top off the system, and this included the small amount of fluid that was loss during the install. I wasn't able to drain the tranny completely because the drain bolt was on extremely tight, so I only added about 3/4 of a quart to the system. I'll have to go to a shop where they can bust off that drain bolt so I can put in new ATF.

[grantizzle]

I'm looking into adding two coolers to my '06... where would you mount them if you didn't mind drilling into the frame?

[blueintegraboy]

Drove cross country with a fully loaded uhaul trailer. The Pilot held up very well.

[justrfb]

Thanks so much for this information. I have one question between this thread and the hitch mounting thread... What about controlling the brakes on the trailer from inside the Pilot? I Saw some 2010 threads talking about finding a connector on the harness up front to put brake controller box in the whole system. Thanks for your reply...

Sincerely,
Rich